KUNBUS GmbH I Heerweg 15c I 73770 Denkendorf I Germany I info@kunbus.com I revolution.kunbus.com

DON´T JUST CLAIM IT - MAKE IT !INDUSTRY 4.0

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In launching Revolution Pi, we have brought an open, modular and in-expensive industrial PC based on the established Raspberry Pi to the market. Equipped with Raspberry Pi Compute Module, the base modules can, depending on requirements, be expanded seamlessly using approp-riate I/O modules and fieldbus gate-ways.

Ba s e d o n t h e R a s p b e r r y P i Compute Module, we have deve-loped an industrial PC composed of open hardware and software meeting the EN61131-2 stan-

dard. Thanks to the modular structure, Revolution Pi can, depending on custo-mer requirements, be supplemented by digital or analog I/O modules respectively as well as appropriate fieldbus gateways to connect it to an industrial network.

Installed in a DIN rail housing, the base modules of the Revolution Pi already have USB, Ethernet and HDMI connections. The base modules and expansion modules are supplied with 24 volts which is the norm in the industry.

In addition to revealing the circuit dia-grams, we are rigorously pursuing the Open Source concept within the soft-ware. The established Raspbian operating system from Raspberry Pi, including the drivers for the expansion modules, are preinstalled. Using Raspbian ensures that basically any software or application run-ning on Raspberry Pi will also run on Revo-lution Pi. Full root access allows obstacle-free programming and implementation of customised programs. By cooperating with various software manufacturers, we provide inexpensive and powerful control and SCADA software for users preferring

off-the-peg software solutions. As a result, Revolution Pi can be developed into an in-dustrially viable small control system.

One of our aim is to provide a tool with Revolution Pi enabling companies to offer new sales opportunities, such as for ex-ample Cloud Services. Revolution Pi ena-bles the development of business models and services that open up new markets. Value added chains of companies using Re-volution Pi can be shifted significantly.

An online forum networks Revolution Pi developers and users from all over the world. Problems, solutions and suggesti-ons for improvements can therefore be ex-changed quickly, openly and easily.

Information & technical data on the base modules of Revolution Pi

THE HEART OF THE REVOLUTION MODULAR DESIGN SOFTWAREFind out more about the expansion modules available

Revolution Pi is more to us than just a de-vice. We believe it is time to break down the fossilized structures within the indus-try with the Open Source concept. We will reveal our source code and all the circuit diagrams belonging to Revolution Pi de-vices. Our customers should not be limited

to our ideas and solutions. This allows you to give free rein to your own ideas. If the ideas are then exchanged just as freely with other users on the Revolution Pi plat-form, a strong community will develop. We will provide the tools for such networking with Facebook, video channels, forums and

blogs. In the future, there will be an app store where you can search for solutions or provide them yourself. Together we are strong and can invent brilliant contribu-tions for the challenges of the 4th indust-rial revolution.

Revolution Pi - more than just a device

Raspberry Pi has had an impressive career ever since its launch early 2012. By the end of 2020, the small and inexpensi-ve single-board computer was sold more than 36 million times.

Behind the development of Raspberry Pi was the idea of producing an inexpensive and simply constructed PC that could introduce kids and teenagers to the world of programming. Even though a great majority of Raspberry Pis in circulation today are used as a media centre at home, Raspberry Pi is also found increasingly in test environments and laboratories in the industry.

Raspberry Pi comes in a variety of versions. We at KUNBUS have decided in favour of the lesser known variant going by the name of Compute Module. Why? Quite simply because by using Compute Module, Raspberry Pi is limited to the most essential. We therefore had sufficient leeway to design its connections etc. in an industrially viable way. Multiple versions of the Compute Module, one with a single-core processor, the others with quad-core processors, are available.

With the presentation of the new Compute Module 4 last year, the start signal was given for the development of the new RevPi 4. Please check and bookmark our Revolution Pi website or follow us on LinkedIn for the latest updates and additions. Then you can be sure not to miss anything.

Why Raspberry Pi ?

Raspberry Pi Compute Module 1, 3 and 3+.

New Modules

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Software Special

RevPi Connect+ with pre-installed CODESYS Runtime license

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* 2 x 500 mA USB output current are only available with output voltages >11 V. The bridging time of voltage drops lasting at least 10 ms required by En 61131-2 is only guaranteed for supply with 20.4 to 28.8 V. This time reduces significantly for 12 V supply, especially when accessing power from

the USB sockets.

RevPi Connect - for all who need more interfaces The RevPi Connect pays tribute to tho-

se users who want to use the Revolution Pi System as an IIoT gateway. Therefo-re, the base module was supplied with even more interfaces. Equipped with the Compute Module 3 resp. 3+, the device has a quad-core processor with 1.2 GHz, 1 GB RAM and up to 32 GB eMMC flash memory.

Two Ethernet interfaces enable the device to be simultaneously integrated within the automation network and the IT network to transmit machinery data from, for example, the shop floor to

the Cloud or a superordinate IT system. A hardware watchdog allows the RevPi Connect to be used anywhere, even in areas that are difficult to access. The hardware watchdog monitors the sta-tus of the RevPi Connect, a relay output serves to ensure that connected devices or expansion modules can be monitored or reset respectively. The RevPi Connect ad-ditionally has a 24 V input to receive shut-down signals of an UPS.

Instead of having two PiBridge con-nectors at the top as with the RevPi Core 3 or RevPi Core, the RevPi Connect

has one PiBridge and one ConBridge connector each. While the PiBridge is responsible for connecting the various IO expansion modules and fieldbus gate-ways, a CAN bus and M-Bus expansion module can be connected via the Con-Bridge. In the future, further expansion modules for different radio standards will follow which can exclusively be connec-ted via the ConBridge.

The RevPi Connect also has a 4-pole RS-485 interface on the front, for example to connect Modbus sensors.

RevPi Connect and RevPi Core are the central processing units of our modu-lar system. By using the Raspberry Pi Compute module, the devices are large-ly compatible with a Raspberry Pi model 3/3+ and Raspberry Pi B+.

A very important element of our Revolution Pi base modules are their power supply units. To en-sure that heat losses are kept to a minimum, we have used the most

advanced and highly efficient DC-DC conver-ters (overall efficiency > 80%), which genera-te the necessary operating voltages from the standard 24 V in industrial switching cabinets.

However, the base modules not only run within the standardised voltage range from 20.4 V to 28.8 V, but at just 10.7 V supply voltage as well*. Thus, car batteries or solar

power systems can also be used as a voltage source. At 24 V supply, the devices can with-stand a voltage drop of 10 ms without dis-ruptions (at full load of the USB sockets) and even 25 ms without load at the USB sockets. The power supply voltage and a functional earthing are connected from below using a very robust connector.

A complex suppressor circuit guarantees un-impaired function even in the case of massive disruptions on the power supply line, provi-ded that the functional earthing is connected. Lightening strikes or adjacent welding units were simulated in a certified test laboratory and could not affect the devices.

At the front are two USB-A sockets for con-necting USB 2.0 client devices. Both sockets supply the full 500 mA current on the 5 V con-nections. As a result, USB hard disks or surf

sticks can also be easily connected without an external, active hub. The micro-USB socket in the middle is used to connect a USB host sys-tem (normally a PC) and switches the system to the passive memory card mode. In this way, a PC can access an installed eMMC flash me-mory and store software there, for example.

A LAN can be connected at the RJ45 Ether-net socket. Alternatively, the connection to a LAN can be established via a WLAN-USB dongle. USB and Ethernet connections have a suppressor circuit. Irradiations or ESDs cannot harm the Revolution Pi system.

The Broadcom processor of the Compute Module provides h igh-resolut ion gra-phic functions. For this reason, the Revo-lution Pi base modules are fitted with a micro-HDMI socket at the top that can be used to connect a monitor with sound output. Thus,

a fully equipped PC is available together with a mouse and keyboard.

The PiBridge is the data highway intercon-necting the individual modules of Revolution Pi. Two adjacent modules on the top of the housing are each interconnected via a system connector.

Revolution Pi includes Raspbian as an opera-ting system by default (a Debian variant) with a real-time patch of the kernel. Further infor-mation on software, drivers etc. can be found on page 5.

The base modules - the foundation of the revolution No secrets - The circuit diagrams of the base modules are disclosed.

At 45 mm, the RevPi Connect is twice as wide as the RevPi Core.

Available expansion modules

Name Function Item no. RevPi Connect+ / Connect RevPi Core 3+ / Core 3 RevPi Core

RevPi DIO Digital IO module 100197 X X X

RevPi DI Digital Input module 100195 X X X

RevPi DO Digital Output module 100196 X X X

RevPi AIO Analog IO module 100250 X X X

RevPi MIO Analog & digital IO module 100323 X X X

RevPi Gate PROFINET IRT Gateway PROFINET IRT Device/Slave 100074 X X X

RevPi Gate PROFIBUS Gateway PROFIBUS Slave 100069 X X X

RevPi Gate EtherNet/IP Gateway EtherNet/IP Adapter/Slave 100066 X X X

RevPi Gate DeviceNet Gateway DeviceNet Adapter/Slave 100071 X X X

RevPi Gate EtherCAT Gateway EtherCAT Slave 100073 X X X

RevPi Gate POWERLINK Gateway POWERLINK CN/Slave 100076 X X X

RevPi Gate SERCOS III Gateway SERCOS III Slave 100075 X X X

RevPi Gate Modbus TCP Gateway Modbus TCP Slave 100088 X X X

RevPi Gate Modbus RTU Gateway Modbus RTU Slave 100090 X X X

RevPi Gate CANopen Gateway CANopen Slave 100070 X X X

RevPi Gate DMX Gateway DMX Master/Slave 100237 X X X

RevPi Gate Serial Gateway Serial Slave 100068 X X X

RevPi Con M-Bus Wireless M-Bus module (868 MHz) 100281 X

RevPi Con M-Bus VHP Wireless M-Bus module (169 MHz) 100282 X

RevPi Con CAN CAN bus module 100286 X

Interfaces (quantity)

Specifications

RevPi Connect+ / Connect RevPi Core 3+ / Core 3 RevPi Core

RJ45 Ethernet ports (10/100 Mbit/s) 2 (each with its own MAC address)

1 1

USB 2.0 socket 2 2 2

Micro HDMI socket 1 1 1

Micro USB 2.0 socket (for firmware uploads only) 1 1 1

RS485 screw terminal (4 pole) 1 - -

PiBridge (for RevPi expansion modules) 1 2 2

ConBridge (for RevPi Con expansion modules) 1 - -

24 V input for shutdown signal of an UPS 1 - -

Freely programmable relay switching contact 1 - -

RevPi Connect+ RevPi Connect RevPi Core 3+ RevPi Core 3 RevPi Core

Processor BCM2837B0 BCM2837 BCM2837B0 BCM2837 BCM2835

Number of cores 4 4 4 4 1

Clock rate 1.2GHz 1.2GHz 1.2GHz 1.2GHz 700 MHz

RAM 1 GB 1 GB 1 GB 1 GB 500 MB

eMMC flash memory 8 GB / 16 GB / 32 GB 4 GB 8 GB / 16 GB / 32 GB 4 GB 4 GB

Power supply 12 - 24 V DC 12 - 24 V DC 12 - 24 V DC 12 - 24 V DC 12 - 24 V DC

Size (L x W x H) 111 x 45 x 96 mm 111 x 45 x 96 mm 111 x 22.5 x 96 mm 111 x 22.5 x 96 mm 111 x 22.5 x 96 mm

Operating temperature -40 °C…+55 °C -40 °C…+55 °C -40 °C…+55 °C -40 °C…+55 °C -40 °C…+55 °C

Storage temperature -40 °C…+85 °C -40 °C…+85 °C -40 °C…+85 °C -40 °C…+85 °C -40 °C…+85 °C

Humidity 93 %, non-condensing 93 %, non-condensing 93 %, non-condensing 93 %, non-condensing 93 %, non-condensing

Protection class IP20 IP20 IP20 IP20 IP20

ESD protection 4 kV/8 kV 4 kV/8 kV 4 kV/8 kV 4 kV/8 kV 4 kV/8 kV

EMI tests Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2)

Surge/Burst tests Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2) Passed (acc. to EN61131-2 and IEC 61000-6-2)

CE Yes Yes Yes Yes Yes

RoHS Yes Yes Yes Yes Yes

UL Yes, UL-File-No. E494534 Yes, UL-File-No. E494534 Yes, UL-File-No. E494534 Yes, UL-File-No. E494534 Yes, UL-File-No. E494534

Operating system Customized Raspbian Customized Raspbian Customized Raspbian Customized Raspbian Customized Raspbian

Base modules - facts & figures

Analog I/O modules

RevPi Core 3, RevPi AIO and RevPi MIO on DIN rail.

It is not easy at all to integrate a device into an indus-trial network. Special protocols are often used for data transmission, such as PROFINET or PROFIBUS. When using our gateways – called RevPi Gate – integrating Revolution Pi into an industrial network is however no problem.

Like all Revolution Pi expansion modules, the gateways are also connected to the base module via the over-head PiBridge connector. Thus, up to two gateway mo-dules (only applies for RevPi Core 3/3+) can be used per system. These, like all modules, are supplied with

24 volts that is the norm within the industry.

We have currently set the cycle time between the base modu-le and a gateway to 5 ms by means of drivers. Though the gate-way modules could reach cycle times of less than 2 ms, it would burden the system load of the base module disproportionately. For the lower the cycle times are set in the driver, the greater the system load is of the device that has to be expended for this process.

We currently offer gateways for the network protocols shown below. All module variants have been tested and certified by the respective user organisations:

To transform Revolution Pi into an industrial control unit, various di-gital I/O modules, amongst other things, can be connected to the base modules.

The I/O modules come in three versions. All have the same 28-pin I/O connector at the front (connector with two rows of 14 pins each – two suitable

14-pin socket connectors with spring clamp contacts for the connection of up to 1.5 mm² stranded hook-up wires are supplied). Apart from the standard version with 14 digital inputs and 14 di-gital outputs, there are also two special versions that exclusively have either 16 digital inputs or 16 digital outputs. In all three variants, the inputs or outputs are galvanically isolated from the lo-gic component with the PiBridge (600 VRMS isolation voltage). In the standard version, the inputs are also galvanically isolated from the outputs. All three ver-sions are protected against disturbances according to EN61131-2 and can be ope-rated between -40 and +50 °C ambient temperature and up to 80 % relative humidity. The standard version of the module is also fitted with PWM outputs (pulse width modulation) and counter inputs.

The inputs work at 24 V supply with switching thresholds, as required by the EN61131-2 standard for type 1 and type 3. The input current is limited to a maxi-mum of 2.4 mA per input. At 12 V power supply, this standard no longer takes ef-fect. If the power supply voltage should discontinue and fall below 9 V, an alarm is sent automatically to the base module to indicate that the transmitted input val- ues no longer match the reliable thresh- old values as laid down in the standard according to 24 V switching logic. An ad-justable low-pass filter can be used for debouncing input signals. It can always only be switched on simultaneously for all inputs. The filter only passes on input changes if an input assumes a stable sta-te for at least 25 µs, 750 µs or 3 ms. The filter can also be switched off complete-ly. Inputs are protected against static dis- charges, burst and surge impulses in ac-cordance with EN61131-2 requirements.

Each of the outputs can be configured separately as a high-side-switch with up to 500 mA current carrying capacity or as push-pull-output with at least 100 mA current load capacity. All outputs are short-circuit proof independent of the operating mode. A watchdog circuit en-sures that the outputs are set to 0 (safe state), once the STM processor no longer

transmits any data from the PiBridge to the outputs. The outputs are set to 0 also in the event of undervoltage at the pow-er supply connection for the outputs or in the case of overtemperature. These last two error states as well as the triggering of the short circuit fuse per channel are transmitted to RevPi Connect/Core via the PiBridge.

In addition, the outputs can be con-figured so that an open load detection (line break) is also switched on and a cor-responding alarm is transmitted to the RevPi Connect/Core for high-side output type. Just like the inputs, the outputs are also protected against static discharges, burst and surge impulses in accordance with EN61131-2 requirements.

Available for all common industrial network protocols, the RevPi Gates help to integrate Revolution Pi into an industrial network.

Fieldbus connection

Digital I/O module RevPi DIO with 14 inputs and outputs.

Digital I/O modules

The two expansion modules RevPi AIO and RevPi MIO allow the RevPi system to be expan-ded with analog inputs and outputs as well as temperature channels. Just like the digital I/O modules, these analog mo-dules also have a 28-pin I/O connector on the front and are connected to the base modules via the PiBridge. Both are well equipped for tough everyday industrial use and are protec-ted against static discharges, burst and surge pulses in ac-cordance with the EN61131-2 standard.

The RevPi AIO offers 4 analog inputs, 2 analog outputs and 2 analog temperature channels.

The two RTD inputs enable temperatures to be measured with high precision from -165 °C to +600 °C in steps of 0.5 °C using common RTDs sensors like Pt100/Pt1000 probes. The probes can be connected di-rectly to the module with two, three or four cables.

The RevPi MIO supplements our basic modules with 8 ana-log inputs, 8 analog outputs and as a goodie with 4 digital channels that can be individu-ally configured via software either as inputs or outputs and are connected via the 4-pin con-nector on top.

SOFTWARE SPECIAL

With the open-source software Node-RED, the user has a browser-based programming tool at his hand to map (IoT) ap-plication cases quickly and without much effort. In addition to control tasks, Node-RED can also be used to create browser-based HMIs.

The manufacturer-independent IEC 61131-3 automation soft-ware for planning control systems turns the Revolution Pi into a small industrial controller. Thanks to the built-in soft master functionality for various industrial protocols, the Revolution Pi system can be integrated into an industrial network without the use of gateway modules.

Revolution Pi is for starters an open platform upon which everything, from the operating sys-tem to applications, can be installed that also run on a Raspberry Pi.

We have decided to preinstall Raspbian (a Debian variant) with a Real-Time patch of the kernel. In our view, it is the best compromise to

remain as close as possible to the original deve-lopment environment of a Raspberry Pi and still maintain a high level of control over the priori-ties of the tasks that the scheduler manages. The scheduler, which controls the execution of the tasks by the operating system, can be con-figured extensively with this modified kernel to ensure that the delays normally caused by net-

work access and other I/O access operations are avoided. Appropriate drivers for the expansion modules are obviously already preinstalled.

On this basis, you can purchase the Soft PLC from logi.cals among other things from our online shop. These components enable you to have a complete and operational PLC.

But maybe you would also like to write your own software under Linux with Python? Then you can just use our driver and the optimised operating system version to access all process data. For this purpose, we, in a memory area, keep a process image with all the current pro-cess values which can easily be written in or read from.

Open source also with the software

Fully available via the PiCtory functions, Modbus Master and Slave can exchange data cyclically with the process image and therefore with all other SW components. The destination and intervals for communication with the Modbus protocol are freely configurable. It means that, alongside RevPi Gate, there’s an additional low-cost method of connecting a multi-tude of sensors, actuators and controllers to Revolution Pi devices.

By means of software agent that is activated at the start, TeamViewer users can now also reach and remotely control their Revolution Pi devices via the internet. It is made possible by means of a very secure and user-friendly TeamViewer tech-nology to access the RevPi webserver via a browser window. Available therefore are all the functions that can be processed via the server and the ones offering a browser.

logi.CAD 3 is the engineering software for creating control applications meeting IEC 61131-3 for Revolution Pi. Special adaptions of the logi.RTS runtime system for Revolution Pi turn the device into a Soft-PLC for industrial applications.

Revolution Pi is a very flexible solution because we offer a great variety of software ready for use on the Revolution Pi hardware family. If you need an IoT tool or a PLC software - just choose the soft-ware which fits your needs. Here is a list of application programs which are already available for you (additional licensing costs may apply):

Simple configuration with PiCtoryEvery Revolution Pi system is supplied with the PiCtory configuration software. It enables you to define the positioning of hardware modules and the symbolic names of the input and output signals. Furthermore, PiCtory can also be used to configure connected hardware modules or installed drivers.

Revolution Pi is a high grade, modular and expandable system. For examp-le, you can write your own drivers to integrate your special hardware seamlessly into the system. The cen-

tral process image in the memory is the link between all components. The components, no matter whether they are hardware modu-les or software applications, always exchange their data with this process image. However to do so, drivers as well as software applications must know exactly where (at which address in the memory) the individual process values can be found.

PiCtory is a browser application. The server is preinstalled by us on the base modules.

Alternatively, you can also use a PC program (Windows) which installs a small web server.

You can arrange the system you require by drag & drop. Predefined rules help you to position the modules correctly. Unfeasible combinations are detected automatically and prevented. Apart from the expansion modules we provide, you can also add your own modu-les to the configuration tool.

PiCtory also supports you when defining, for example, all I/O signals. You can assign symbo-lic names and define which adapter supplies and retrieves the data. An adapter can be a hardware module on the PiBridge but it can also be a “virtual device” – driver software for example – for which the memory location is reserved in the process image and for which process values can be defined with symbolic names. The finished configuration file is stored as a JSON file.

PiCtory helps you to set up your Revolution Pi system.

Modbus TCP & Modbus RTU

TeamViewer

logi.CAD 3

Node-REDCODESYS

RevPi Connect+ feat. CODESYS

Additionally, the RevPi Connect+ is available with a preinstalled CODESYS Runtime license and offers a real alternative to complex and cost-intensive PLCs. Pro- grammed with CODESYS according to IEC 61131-3, the controller has a 16 GB eMMC memory and is equipped with two RJ45 Ethernet sockets, two USB ports, a 4-pin RS485 interface, a micro-HDMI and a micro-USB socket. Integration into the CODESYS development environment is quick and easy by importing the device description files. Thanks to its modular design, it is possible to equip the RevPi Connect+ with suitable expansion modules such as IOs, fieldbus gateways and radio modules. These can be coupled to the base unit without tools via plug-and-play using a top-mounted connector, just as easily integrated into CODESYS and controlled and configured via the inte-grated development environment (IDE).

RevPi Connect+ feat. CODESYS

github.com/RevolutionPi

linkedin.com/showcase/revolution-pi

youtube.com/RevolutionPi

twitter.com/kunbus_gmbh

facebook.com/RevolutionPi

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The new ones: RevPi Compact & RevPi FlatWith the RevPi Compact and the RevPi Flat,

we are presenting two new devices that – if you compare them with our well-known mo-dules – will catch your eye at first glance with their changed design, their flat construc-tion. This has happened for a good reason: Both modules can thus be easily and space-savingly installed in sub-distribution cabinets, which are usually found in building automa-tion. In addition, they are not modular, but have extensive interfaces directly on board. The RevPi Compact is our slim and cost-effec-tive alternative to the RevPi Connect with its expansion modules and is usually completely sufficient for common automation solutions. Based on the Raspberry Pi Compute Module 3+, it impresses with real industrial suitabili-ty, open-source capability and its high perfor-mance and functionality. The most important interfaces are already integrated.

The RevPi Flat is a versatile, freely program-mable hardware platform developed for the energy industry. The device is also based on the Raspberry Pi Compute Module 3+ as well as Linux and is also WLAN-capable as a no-velty in the RevPi family. The RevPi Flat can be used to implement a wide range of pro-jects, for example for process optimisation, for more efficiency in data handling and for the implementation of new marketing stra-tegies and concepts in the energy industry. Detailed information on both modules, their technical data including interfaces, perfor-mance features, etc. can be found on the pro-duct pages of our website: https://revolution.kunbus.com/revpi-compact/https://revolution.kunbus.com/revpi-flat/

RevPi Compact and RevPi Flat

QR code website